Art or method of and apparatus for casting fluid metals.



0x6. SANDAGE.

ART OR METHOD OF AND APPARATUS FOR CASTING FLUID METALS.

APPLICATION FILED AUG. I. I913.

Patented Oct. 12

2 SHEETS-SHEET I.

In V611 tor:

unrrno s'raaus PATENT canton.

OLIVER G. SANDAGE, OF NEW YORK, N. Y., ASSIGN OR OF TWO-THIRDS IO DOEHLER DIE CASTING COMPAN Y, A CORPORATION OF NEW YORK.

ART OR METHOD OF AND APPARATUS FOR CASTING FLUID METALS.

Application filed August 1,

To all whom it may concern:

a citizen of the United States, residing at the borough of Brooklyn, in the city ofv New York, county of Kings, and State of New York, have invented certain new and useful lm'provementsin the Art or Method of and Apparatus for Casting Fluid Metals, of which the following is a specification, reference being had therein to the accompanying drawings, which form a part thereof.

My invention relates to improvements in the art or method of, and apparatus for, casting fiuid metals, and more particularly to an artor method and apparatus for use in connection with steel dies utilizing air or other gases under pressure for forcing the metal into the mold. I

The main object of the invention is to provide a method of castingfiuid'metals utilizing a bottom pour melting pot, where-. by that portion of the metal delivered to the die ismaint'ained at the proper-temperature to insure a ready flow of the metal toall parts of the die while excluding dross, 0X- ids or other impurities from the metal delivered'to the die.

A still further object is to provide such a method whereby excessive splashing of the metal in the pot with the introduction of the gaseous charge under pressure will be avoided, and the oxidation of the metal from said gas reduced to a minimum.

A still further object is to provide a method of this character wherein the gas under pressure will be applied to the metal and the metal delivered to the mold or die thereunder in a manner to insure the delivcry of the molten metal substantially instantaneously and in such volume as will completely fill the entire mold or die.

A still further object is to provide an apparatus by means of which my aforesaid method or art may be conveniently practised without likelihood of the escape of the metal while passing from the melting pot to the mold or die. V

A still further object is to provide an apparatus wherein the mold or'die may be rapidly brought into the operative relation 'to the melting pot, and secured relative thereto in a manner to insure a sufiiciently Specification of Letters Patent. 7

Patented Oct. 12, 1915.

1913. Serial N0. 782,393.

tight fit to prevent the escape of the metal between the gate of the die and the outlet of the melting pot.

A still further object is to provide an apparatus of this character wherein the pressure within the melting pot and the delivery of the metal to the die may be controlled in a manner to insure the timely delivery of the molten metal to the dieunder the proper conditions.

A still further object is to provide an apparatus so constructed as to permit the rapid charging of the die and the ejection of the castlng to insure high capacity'of the machine.

A still further object is to provide an apparatus which may be adjusted to adapt it to dies of dilferent sizes or to insure the proper fitting of a die with relation to the melting pot.

A still further object is to provide in connection with an apparatus of this character, a sprue former, by means of which the metal may be delivered from the melting pot to the die, said sprue former being capable of removal from the die to prevent freezing of the ingate of the die.-

A;'still-g.further object is to provide an ape .paratus of'this. character wherein the operator Wlll be protected from possible injury due to the escape of molten metal between the ,die and the melting pot.

A still further object is to provide an apparatus of this character wherein the various operations may be conveniently controlled or practised by the operator.

A still further object is to provide an apparatus wherein no sprue cutter is required, the gate controlling the outlet of the melt-- ing pot acting to separate the metal entering the die from that in the melting pot. And

a still further object is to provide an apparatus wherein the gate controlling the out let of the melting pot will be automatically closed and normally-maintained closed to prevent the escape of the metal from the potexcepting when the die is in the operative relation thereto.

The invention consists primarily in a method or art of casting fluid metals embodying therein the subjection of a confined mass of molten 'metal contained in a bottom pour melting pot to gas under pressure thereafter permitting a small portion of the molten metal to flow under said pressure through the outlet of said pot intoa mold and thereafter simultaneously closing said port and forcing the metal therein outwardly of said melting pot; and in such novel steps as are hereinafter set forth and described; and in the novel features of conscale, showing the mold in position to have the moltenmetal charged thereinto, the

guard being indicated by dotted lines in' the lowered position; Fig. 3 isa detail view in section of, the removable sprue former removed from a mold, the sprue being shown in connection with a portion of the; mold; and Fig. 4 is a detail front view of the means for forcing the mold toward the melting-pot, a conventional mold, and a portion ofthe melting'pot also being shown. Like letters refer to like parts throughout the several views.

Heretofore in the art of casting fluid metals under fluid pressure, it has been the practice to subject the metal in acharging pot drawing its supply of metal from a melting pot, to the action of air under pressure in a manner to force a portion of the fluid metal contents upwardly into the mold, a sprue cutter being used to prevent back flow of the metal to the die. Where the metal has been forced directly from the melting pot into the mold, thls has'been the usual, and 'so far as I am aware, theonly method ever suggested or attempted.

Contradistinguished from this method is a method bywhich a metal is fusedin a crucible apart from the mechanism for charging the mold, and delivered in limited quantities to a bottom pour pressure chamber from whence the entire charge of metal is forced under air pressure into the mold. I

In actual practice, the first method above referred to has been found impracticable because of the rapid deterioration of the metal in the charging pot or pressure chamber;

, the difficulty" of keeping the metal in the charging'pot or chamber at the right temperature, and a marked tendency of the metal to back flow forming invisible blow lioles'in the castings produced. The castings also frequently contained flaws resulting from the presence of oXids in the charging pot or chamber.

While the second method above "referred to possessed noneof the disadvantages above enumerated, and was especially suited for use in making casting of the higher fusing metals, the operation of a machine capable of use in practising that method -was too slow for use in connection with metals and alloys having a low fusing point.

To obviate the difficulties enumeratedabove, I employ a method or art in which the metal for charging is forced directly from a bottom pour melting pot int-o the mold by means of air or other fluid pressure, thus securing the advantages of an avoidance of contact of any portion of the metal to be charged into a mold with the ,air or other gas under pressure; an ability to maintain any portion of the metal in the melting pot to be charged into a mold at the desired temperature up to the time it is to be so charged; the automatic separation of the oXids and other dross from the metal adjacent the outlet port and its accumulation near the top of the melting pot Where it will in a measure protect the contents of the melting pot from the air or other gases; and the instantaneous delivery of sufficient metal to fill the mold without possibility of back flow, the quantity of metal delivered being coincident with the capacity of the .mold. As a further incident I have found little or no tendency ofthe metal to splash, which I attribute in part to a possible'sluggishness of the metal toward the top of the melting pot due to lower temperatures at this point.

In the practice of my invention, I fuse a mass of metal such as aluminum, or the white metal alloys, contained in a bottom pour melting pot, by impinging a melting flame upon the pot adjacent the outlet port. This brings the metal toward the bottom of the pot to the desired molten state when it will readily flow, the metal in the upper portionof the pot being more sluggish because further removed from the heating flame. The outlet port is normally closed within said pot except when this port is opened. The melting pot being closed at the top, air or other fluid pressure may be v 'so that the entire mass of metal is confined i readily introduced thereinto for delivering a charge lntothe mold. To insure practically an instantaneous delivery of the entire charge nto the mold and thus avoid any portion thereof entering the mold under.

gravity andsetting by chilling before the mold is filled, I admit the air or other gas under pressure to the melting pot before opening the outlet port, or while the entire mass is thus confined. To relieve this pot from unnecessary stress, I bring the ingate of the mold into position relative to the melting pot outlet port, before subjecting" the mass to air or othergas pressure, and i when the required pressure is developed in the melting pot, immediately open said outlet port.

The opening of the outlet port will permit the air or other gases to instantly expand, forcing a small portion of the mass of molten metal in a substantially solid stream and without spraying into, and compacting it within, the mold. The outlet port is then immediately closed, and the pressure within the melting pot relieved by venting. It will be observed that the metal delivered from the melting pot is drawn fromthe heat Zone of highest temperature, and that this metal does not come in contact with any portion of the air or gas used for forcing it from the pot.

Castings made by my method or art have a smooth finish and sharp outlines, and are free from dross, oxids, blow holes or other apparent or concealed defects.

The closing of the outlet port separates the metal of the casting from that in the pot, the valve acting as a sprue cutter. The high temperatures about the outlet port permit the free actuation of the valve either in opening or closin Fresh ingots 0 metal are introduced into the melting pot from time to time to maintain a suflicient mass of molten metal therein.

The essentials of my method or art are the fusing and maintenance of a mass of metal in a bottom pour melting pot; the

closing of the outlet port of said pot so as to normally confine the mass of metal within said melting pot inert; the introduction of air or other gases under pressure to said pot; the subsequent expansion of this air or other gas through the opening of the outlet port thus permitting a small portion of the mass of molten metal to flow under pressure 7 through said port into a mold; the closing of said port, pot.

In the practice of the herein described art or method, I employ an apparatus as shown in the accompanying drawings, embodying therein a furnace having an outer shell a provided with a refractory lining Z). Mounted and suitably braced within said shell is a bottom pour melting pot 0, having a constricted lower portion, the walls of and the venting of the melting which converge toward the outlet port (Z.

The top of the said melting pot is closed and sealed against heavy pressures by the fixed top a and the removable top section 7, held in place and sealed by the clamp bar f, this removable top section being provided to facilitate the introduction of metal into the melting pot.

to normally close the valve. The stem k.

is enlarged within the melting pot, as at 71. to secure stiffness and avoid weakening through contact with the molten metal. The melting pot is without obstruction save the valve stem. The valve proper It and port cl are slightly tapered to insure a proper seating of the valve, and said valve is elongated to project through said port to avoid any possibility of the port being clogged, although the high temperature about said port would prevent chilling of the metal therein.

Discharging into the upper portion of the melting pot c is a pipe line 7' having a three way valve is in its length, which valve is used to control the pressure within said pot.

I provide an ordinary pressure gauge j communicating with the melting pot, for indicating the pressure within the pot. The exterior of the bottom of the melting pot 0 about the port d is planed and finished as at permit the convenient ejection of the casting.

These tracks are supported by adjustment screw rods 0 p, so that the height of these tracks may be regulated to accommodate the apparatus to molds of different dimensions.

Arranged directly below the outlet port d is a vertically movable platform 9 adapted to engage the die and force it toward the melting pot, to form a metal to metal joint between the die and the melting pot. This platform is supported by a screw threaded stem 9 having adjustably mounted thereon the cam disk 9 acted upon by the cooperating lifting cam 1' having an actuating handle 'I-. The tracks m m and cam r are supported by the bed 8 of the machine. The screw rod 0 is adapted to be actuated by the wheel handle 0.

The tracks on m are provided withsuitable stops m m for limiting the reciproc'aa tcry movement of the bed If, by means of which the mold n is mounted on the said tracks. v

To avoid possibility of escaping metal be;

ing thrown upon the operator, I provide the shield u slidable within the shell a so as to afiord clearance for the mold in its move- Y ment along the tracks m m. This shield is provided with an operating handleu moving in a bayonet slot 21, in the shell a, so as to permit the locking of the shield in the raised position. v

v To avoid the setting or freezing.of the metal in the ingate ofa mold, I preferably provide the mold with a removable ingate comprising a downwardly converging ta-' pered head '1; adapted to fit within a correspondingly tapered opening a in the die proper. This head is provided with a downing in a bayonet slot u in the shell a, so as to give theproper draw from the sprue ini dicated at 'w.

paratus in the practice of my art or method is substantially as follows :The die nbeing closed, the head '0 is inserted in the opening a, and the die advanced upon the tracks m m untilsaid ingate o is directly below the outlet port (1. The cam r is then turned by means of its handle 1" to force the die into the necessary close contact .with the seat d through the platform 9, screw g and cam.

9 If the desired close contact is not thus secured, the tracks may be raised by means of the rods 0 p. The mold having been properly set, the shield uis lowered and the valve is actuated to admit the air or other gas under pressure into the upper part of the melting pot a. The lever Z is then usedto raise the valve h and open the outlet port cl whereupon a charge of metal from the bottom of the melting pot will be instantaneously forced'into the mold through said port, through the expansion of said air or other gas. The handle I is immediately released, thus permitting the spring rigging 71' to automatically actuate the valve 72. to closesaid. port (Z. Substantially simultaneously with the closing of said port, the valve is is actuated to vent the melting pot and relieve the pressure therein. The casting being completed, the shield at is raised and locked in the raised position, the cam r returned to normal to lower the mold, and the mold 'drawn'to the position shown in Fig. 1, to a permit the ejection of the casting. Before opening the mold, the removable sprue former isturned by means of the handle 12 thus causing-the cams o n to raise the head 4), drawing the tapered opening 2) away from the sprue.

The operations above described may be of rapidly repeated by an operator in the order specified to permit the, rapid production of a number of castings from the same mold.

It is not my intention to limit my invention to the precise details .of construction shown in the accompanying dr'awings, it bemy invention.

- Having described my invention, what I claim as new and desire to have protected by Letters Patent, i's v i I i 1. An art or method of casting fluid met- 'als embodying therein the subjection of a ing apparent that such may be varied without departing from the spirit and scope of l confined mass of molten metal contained in a bottom pour'melting pot to fluid under pressure, thereafter permitting a small portion of the molten metal to'flow downwardly through the outlet portof said melting pot and into a mold under such pressure and thereafter simultaneously closing said port and forcing the metal therein outwardly of said melting pot.

. 2-. An art or method of casting fluid metalslembodying therein the subjection of a confined mass of molten metal contained in a bottom pour melting pot to fluid under pressure, permitting said air or gas to expand by permitting the molten-metal to flow through the outlet port of said melting pot into a mold and thereafter simultaneously closing said port and forcing the metal therein outwardly of said melting pot.

3. An art or method of casting fluid metals-embodying therein the subjection of a confined mass of molten metal contained in a bottom pour'melting pot to fluid under pressure, thereafter permitting a small portion of the molten metal to flow downwardly through the outlet port of said melting pot and into a mold under such, pressure, simultaneously closing said port and forcing the metal therein outwardly of said melting pot,

' and relieving-the pressure within said melting pot.

4. An art or method of casting fluid'm'etals, embodying therein the fusion of a mass of metal in a bottom pour melting pot by a flame directed adjacent the outletport of said pot, normally confining said metal within said pot, subjecting the entire mass of molten. metal while so confined tofluid under pressure, thereafter permitting a small portion of-the molten metal to flow downwardly through the outlet port of said melting pot and into a mold under such pressure and thereafter simultaneously closing said port and forcing the metal therein outwardly of said melting pot.

5. An art or method of casting fluid metals, embodying therein the fusion of a mass of metal in a bottom pour melting pot by a flame directed adjacent the outlet port of said pot, normally confining said metal within said pot, sub ecting the entire mass of molten metal while so confined to fluid under pressure, thereafter permitting a small por,

tion of the molten metal to flow downwardly through the outlet port of said melting pot and into a mold under such. pressure, simultaneously closing said port and forcing the metal therein outwardly of said melting pot, and relieving the pressure within said melting pot.

6. An apparatus for casting fluid metals embodying therein a melting pot having an outlet port in the bottom thereof, said outlet port having a beveled valve seat about same and within said pot,,a furnace adapted to fuse metal in said pot, a valve having avalve mechanlsm for controlling the flow of air or other gases to and from said pot, and means whereby a mold may be supported with its ingate in communication with said outlet port.

7. An apparatus for casting fluid embodying therein a melting pot having side walls converging toward the bottom thereof and an outlet port in the bottom thereof, said port having a beveled valve seat about same within said melting pot, a furnace.

adapted to fuse metal in said pot, a valve having a tapered portion adapted to conform to said valve seat, and an elongated extension below said tapered portion and projecting through said port, said valve normally. closing said outlet port, means for ac-' tuating said valve, a pipe line adapted to deliver air or other gases under pressure to said melting pot, a valve mechanism for outlet port in the bottom thereof said portcontrolling the flow of air or other-gases to and from said pot, and means whereby a mold may be supported with its ingate in communication with said outlet port.

8. An apparatus for casting fluid metals embodying therein a melting pot, having an having a beveled valve seat about same within said melting pot, a burner, the outlet openings of which are directed toward and about the bottom of said melting pot, a valve having a tapered portion adapted to conform to said valve seat, and an elongated extension below said tapered portion and projecting through said port, said valve normally closing said outlet port, means for actuating said valve, a pipe line adapted to deliver air or other gases under pressure to said melting pot, a valve mechanism for controlling the flow of air or other gases to and from said pot, and means'whereby a mold may be supported with its ingate in communication with said outlet port.

9. An apparatus for casting fluid metals metals embodying therein a melting pot having an outlet port in the bottom thereof, said outlet port having a beveled valve seat about same and within said pot, a furnace adapted to fuse-metal in said pot, a valve having a tapered portion adapted to conform to said valve seat, and an elongated extension below said tapered portion and projecting through said port, said valve normally closing said outlet port, means for actuating said valve, a pipe line adapted to deliver air or other gases under pressure to said melting pot, a valve mechanism for controlling. the flow of air or other gases to and from said pot, means whereby a mold may be supported with its ingate in communication with said outlet port, a support for a mold extending below said outlet port of. said melting pot, and means for adjusting said support toward and from said melting pot whereby said support'may be adjusted to molds of different sizes. j

10. An apparatus for casting fluid metals; embodying therein a melting pot having an outlet port in the bottom thereof, said outlet port having a'beveled valve seat about same and within said pot, a furnace adapted to fuse metal in said pot, a valve having a tapered portion adapted to conform to said valve seat, and an elongated extension below said tapered portion and projecting through said port, said valve normally closing said outlet port, means for actuating said valve, a pipe line adapted to deliver air or other gases'under pressure to said melting pot, a valve mechanism for controlling the flow of air or other gases to and from said pot, and means whereby a mold may be supported with its ingate in communication with said outlet port.

11. An apparatus for casting fluid metals embodying therein amelting pot having an outlet port in the bottom thereof, said outlet port having a beveled valve seat about same and within said pot, a furnace adapted to fuse metal in said pot, a valve having a tapered portion adapted to conform to said valve seat, and an elongated extension below said tapered portion and projecting through said port, said valve normally closing said outlet port, means for actuating saidvalve, a pipe line adapted to deliver .air or other gases under pressure to said melting pot, a valve mechanism for controlling the flow of air or other gases to and from said pot,

means whereby a mold may be supported outlet port in the bottom thereof, said outlet port having a beveled valve seat about same and within said pot, a furnace adapted to fuse metal in said pot, a valve having atapered portion adapted to conform to said valve seat, and an elongated extension below said tapcred portion and projecting throughsaid port, said valve. normally closing said outlet port, means for actuating said valve, a

pipe line adapted to deliver air or other gases under pressure to said melting pot, a valve mechanism for controlling the flow of air or other gases to and from said pot, means whereby a mold may be supported with its ingate in communication with said outlet port, tracks extending below said melting pot and adapted to supporta mold, and adjustment rods adjacent the ends of said tracks whereby said tracks may be said port, said valve normally closing said outlet port, means for. actuating said valve,

a pipe line adapted to deliver air or other gases under pressure'to said melting pot, a

valve mechanism for controlling the flow of air or other gases to and from said pot, means whereby a mold may be supported with its ingate in communication with said outlet port, means for adjusting said support toward and from said melting pot whereby said support may be adjusted to molds .of different sizes, a vertically slidable screw rod, a platform carried thereby-adapted to engage the mold, a cam plate adjustably mounted upon said screw rod, a cam c0- operating with said cam plate supported by the frame of the machine, and an operating handle for said last named cam whereby said platform may be raised or lowered to force the ifiold into intimate contact with the melting pot.

14. An apparatus for casting fluid metals embodying therein a melting pot having an outlet port in the bottom thereof, said outlet port'having a beveled valve seat about same and within said pot, a furnace adapted to fuse metal in said pot, a valve having a tapered portion adapted to'conform to and seat upon said beveled 'valve seat and an elongated portion below said tapered portion and extending through said port, a spring rigging acting on said valve-to cause it to normally close said outlet port, means for actuating said valve, a pipe line adapted to deliver air or other gases under pressure to said melting pot, a valve mechanism for controlling the flow of air or other gases to and from said pot, and means whereby a mold may be supported with its ingate in communication with said outlet port.

I 15. An apparatus for casting fluid metals embodying therein .a melting pot having an outlet port in the bottom thereof, said porthaving a beveled valve seat about same within said melting pot, a furnace adapted to fuse metal in said pot, a valve having a tapered portion adapted to conform to said valve seat, and an elongated extension below said tapered portion and projecting through said port, said valve normally closing said outlet port, means for actuating said valve, a pipe line adapted to deliver air or other gases under pressure to saidmelting pot, a valve mechanism for controlling the flow of air or other gasesto and from said pot, tracks extending below said melting pot, and a mold carrier slidably mounted thereon whereby a mold may be brought into the operative relation to said melting pot or withdrawn therefrom to permit the ejection of a casting.

16. An apparatus for casting fiuidmetals embodying therein a melting pot having an outlet port in the bottom thereof, said port having a beveled valve seat about same within said melting pot, a furnace adapted to fuse metal in said pot, a valve having a tapered portion adapted to conform to said valve seat, and an elongated extension below said tapered portion and projecting through said port, said valve normally closing said outlet port, means for actuating said valve,

a pipe line adapted to deliver air or other gases under pressure to said melting pot, a valve mechanism for controlling the flow of air or other gases to and from said pot, tracks extending below said melting pot, a mold carrier slidably mounted thereon whereby a mold may be brought into the operative relation to said melting pot or withdrawn therefrom to permit the ejection of a casting, and stops carried by said tracks for limiting the direct and return movement of said mold carrier to accurately position it with relationto said outlet port and to check its movement away from said melting pot.

17. An apparatus for casting fluid metals embodying therein a melting pot having an outlet port in the bottom thereof, said port having a beveled valve seat about same within said melting pot, a furnace adapted to fuse metal in said pot, a valve having a tapered portion adapted to conform to said valve seat, and an elongated extension below said tapered portion and projecting through said port, said valve normally closing said outlet port, means for actuating said valve, a pipe line adapted to deliver air or other gases under pressure to said melting pot, a

valve mechanism for controlling the flow of air or other gases to and from said pot, means whereby a mold may be supported with its ingate in communication with said outlet port, and a movable shield adapted to be interposed between said melting, pot and the operator when said mold is in the operative relation to said melting pot, and

to be withdrawn to permit the passage of said mold from beneath said melting pot.

18. An apparatus for casting fluid metals embodying therein a melting pot having an outlet port in the bottom thereof, afurnace adapted to fuse metal in said pot, a valve normally closing said outlet port, means for actuating said valve, a pipe line adapted to deliver air or other gases under pressure to said melting pot, a valve mechanism for controlling the flow of air or other. gases to and from said pot, means whereby a mold may be supported with its ingate in communication with said outlet port, a shell inclosing said melting pot and said furnace, a shield slidable vertically within said shell, said shell having a bayonet slot therein, and

an operating handle carried by said shield and moving in said slot whereby said shield may be raised to permit the passage of a mold under said shell and may be interposed between the melting pot and the operator while the mold is in the operative relation to the melting pot.

19. In an apparatus for casting fluid metals, a sprue former separable from the mold, and adapted to be interposed between the mold and the melting pot, said sprue former comprising a frusto-conical head having an inversely directed frusto-conical opening therein, whereby said sprue former may be fitted accurately to a mold and will draw readily away from the sprue formed thereby.

20. In an apparatus for casting fluid metals, a sprue former separable from the mold, and adapted to be interposed between the mold and the melting pot, said sprue former comprising a frusto-conical head having an inversely directed frusto-conical draw readily away from the sprue formed may be fitted accurately to a mold and will draw readily away fro Inthe sprue formed thereby, said sprue former and said mold beingprovided withcooperating cam sur-' faces for facilitating the raising of said head, and said head being provided with an operating lever handle.

In witness whereof, I have hereunto affixed my signature, in the presence'of two.

subscribing witnesses, this 29th day of July, 1913.

OLIVER G. SANDAGE.

' Witnesses:

G. T. WENTWORTH, CLARICE FRANCK. 

